face mill

[fourperf]

hi guys, I know this probably belongs in the general machining forum but I feel more at home here so I will post it here instead. I primarily machine 6061 but do a bit of mild steel and stainless. I need a recommendation for a face mill and inserts. Any input would be appreciated.

Thanks

Mark

[Doug Tyler]

I have a Mini Mill. I've been using an Iscar Tang Mill
It's a 2.5 inch diameter with 9 cutting edges. You get 4 edges per insert.
Also, you can buy a left hand cutter body to use the additional 4 edges per insert. I haven't seen a face mill yet that can outrun this thing. I've had it running at 5000 RPM and feeding 60 IPM @ .100 depth of cut. The only reason I can't go faster is because the machine is running at 120% load at that speed. Also the finish is glass smooth. Hope this helps.

[fourperf]

Oh, I see I forgot to put in my post that I currently have a face mill for aluminum. I need to buy one only for steel and stainless. I thought when I bought it that different inserts would take care of steel but this particular face mill is only for aluminum.

thanks

mark

[kojack]

Originally Posted by fourperf Oh, I see I forgot to put in my post that I currently have a face mill for aluminum. I need to buy one only for steel and stainless. I thought when I bought it that different inserts would take care of steel but this particular face mill is only for aluminum. thanks mark

here is what I use

http://cgi.ebay.com/ISCAR-Hard-Touch...ayphotohosting

[fourperf]

Originally Posted by kojack here is what I use http://cgi.ebay.com/ISCAR-Hard-Touch...ayphotohosting

what feeds and speeds do you use with that cutter on cr steel? coolant or dry?

thanks

mark

[Cory]

I use this in 2.5" on my VF-1. Probably 95% of the time it's on 6061, and the other 5% is 4140, 4340, and A2. It's worked well for me so far. I run it dry on steel and wet on aluminum.

[fourperf]

Originally Posted by Cory I use this in 2.5" on my VF-1. Probably 95% of the time it's on 6061, and the other 5% is 4140, 4340, and A2. It's worked well for me so far. I run it dry on steel and wet on aluminum.

different inserts?

[rbest27]

Sandvik 245 style
http://www.coromant.sandvik.com/

good all around face mill, long lasting inserts good speeds and feeds

[Geof]

Originally Posted by fourperf Oh, I see I forgot to put in my post that I currently have a face mill for aluminum. I need to buy one only for steel and stainless. I thought when I bought it that different inserts would take care of steel but this particular face mill is only for aluminum. thanks mark

It is possible that you do not need to worry about buying anything new, not even the inserts.

For mild steel try something like 400SFM, and depth of cut around 0.10" to 0.15" and a feed of around 0.005" per tooth, or more, with air blast not coolant.

Stainless is a different ball game: Drop the speed to around 150SFM, the depth of cut to 0.05" but keep the feed above 0.003" but maybe not above 0.005".

Stainless work hardens so you need a DOC and feed that gets underneath the work hardened surface from the previous cut.

Mild steel loses strength when it gets hot while carbided tools can handle high temperatures so you want conditions that create a hot chip, bright blue in appearance.

[Cory]

Originally Posted by fourperf different inserts?

Nope, I actually use the same inserts for aluminum and steel. It seems to work fine. I'm not sure what insert I use specifically (It's coated, I want to say AlTiN since it's purpleish, but not sure).

[fourperf]

I did speak to the manufacturer and they told me only for alum.
I did not realize that when I bought it. I had taken the recommendation from a tooling supplier. I was scared to try it out on steel as the inserts are quite expensive. I figured I would get a recommendation here and maybe find something on ebay (if I was lucky)

thanks

Mark

[shay z]

I recommend the new iscar's new SOF45 mills.

I am using a 80 mm mill on cast iron and stainless steel (1400 mm/min feed on cast iron 3 mm depth and 800 mm/min feed on ss316 castings 2 mm depth).

http://www.iscar.com/Ecat/familyHDR....type/1/lang/EN